Machining of a film-cooling hole in a single-crystal superalloy by high-speed electrochemical discharge drilling

Single-crystal superalloys are typical advanced materials used for manufacturing aeroengine turbine blades. Their unique characteristics of high hardness and strength make them exceedingly difficult to machine. However, a key structure of a turbine blade, the film-cooling hole,needs to be machined in a single-crystal superalloy; such machining is challenging, especially considering the increasing levels of machining efficiency and quality demanded by the aeroengine industry. Tube electrode high-speed electrochemical discharge drilling(TSECDD), a hybrid technique of high-speed electrical discharge drilling and electrochemical machining, provides high machining efficiency and accuracy, as well as eliminating the recast layer. In this study, TSECDD is used to machine a film-cooling hole in a nickel-based single-crystal superalloy(DD6). The Taguchi methods of experiment are used to optimise the machining parameters. Experimental results show that TSECDD can effectively drill the film-cooling hole; the optimum parameters that give the best performance are as follows: pulse duration: 12 ls, pulse interval: 30 ls, peak current:6 A, and salt solution conductivity: 3 m S/cm. Finally, a hole is machined by TSECDD, and the results are compared with those obtained by electrical discharge machining. TSECDD is found to be promising for improving the surface quality and eliminating the recast layer.     

基于动态逆-滑模的高速飞行器控制器设计

吸气式高超声速飞行器巡航状态下飞行环境复杂,建模时存在非线性以及参数摄动.基于小扰动假设的传统经典控制理论难以适应当前任务对鲁棒性的要求,对此提出了一种非线性动态逆-滑模控制律改进方法.通过对吸气式高超声速飞行器模型精确反馈线性化得到解耦形式的线性方程,为速度和高度设计出动态逆控制律来抵消非线性特性,在动态逆的基础上采用滑模变结构来补偿参数摄动带来的误差.仿真结果表明,所设计的控制方法具有良好的动态性能及鲁棒性.     

基于OpenFOAM的真实流体模型库及均相求解器开发

为了正确认识高压环境下的流体非理想性特征,及其对于低温射流喷雾过程的影响作用,将多种不同真实流体模型写入到开源CFD程序OpenFOAM仿真平台中,编译形成具有广泛通用性的真实流体热物理模型库;并将高压下真实流体特征的影响引入到压力修正算法中;开发出适用于描述超临界环境下低温流体流动过程的均相求解器。对高压下流体热物理性质的非理想性,以及超临界环境下的低温液氮射流喷注过程进行研究。结果表明:高压下的真实流体效应主要体现在低温区域,本文所建立的模型库可以在任意热力学状态范围内正确预测流体热物性;基于此模型库所开发的均相求解器可正确预测超临界环境下低温射流的详细流动特征和结构,而理想气体模型则会大幅低估射流核心区密度分布,中心线上误差高达68.9%;综合考虑计算精度和效率,PR EoS及相关模型更适合于这类超临界流动问题的求解;低温射流跨临界喷注中局部区域所发生的虚假沸腾现象会导致射流温升速率降低、体积膨胀速率加快;射流核心区压缩因子明显1,在数值仿真时必须考虑高压环境下的真实流体效应。     

预燃式等离子体射流点火器工作特性实验研究

为解决发动机点火包线小于飞行包线的实际问题,提供等离子体点火技术在航空发动机中的工程应用新思路,论文设计了一种预燃式等离子体射流点火器,实验研究了放电特性和射流特性。结果表明,预燃式等离子体射流点火器与空气等离子体射流点火器相比,在提升射流能量降低电源功率方面有着较大的优势,电流相同时通入甲烷在较大流量时可减小驱动电源功率,总流量为44L/min时,减幅可达14.99%;同时预燃式等离子体射流较空气等离子体射流稳定,且射流长度增加,扩大了点火面积,有利于点火。     

基于PaSR模型的低旋流燃烧大涡模拟

为了深入理解低旋流流场特征和燃烧稳定性,基于OpenFOAM平台,采用动态k方程模型和有限速率PaSR模型对甲烷/空气预混低旋流燃烧进行了大涡模拟,研究了气流入口速度、当量比和压力等流场参数对流场结构和燃烧非稳态特性的影响,分析了流场大尺度结构与火焰相互作用。结果表明,流场结构和火焰抬升高度受入口速度影响较小,流场和火焰形态能够保持自相似性;随着当量比和压力提高,流场扩张性增强并在燃烧区下游产生回流区,火焰稳定不依赖回流区,根部火焰锋面形状由U形转变为W形,火焰抬升高度降低。火焰锋面稳定在剪切层,剪切层产生的周期性有序涡结构引起当地流场速度脉动和火焰表面褶皱,反映了流场非稳态特性;通过剪切层监测点瞬时轴向速度分析,涡结构特征频率随速度增大而提高,由250Hz提高至300Hz,随当量比和压力提高而降低,由250Hz降低至125Hz。     

基于自适应网格的超声速液体射流破碎过程研究

为研究超声速气流中液体横向射流的破碎过程,采用脉冲背景光方法和VOF方法开展了实验和数值研究。为提高液体横向射流中气液界面和气流场特征捕捉的精确性,采用自适应网格技术对于气液界面、激波出现位置进行网格细化,计算得到了较为精细的气液界面、激波特征及涡系结构。研究结果表明:在低成本仿真模拟条件下,利用自适应网格计算得到的射流轨迹和轮廓与实验吻合较好,射流轨迹的最大误差为10%;射流初始段在超声速气流条件下,仍然存在一段高度约为1.9倍喷孔直径且圆柱形态保持较好的连续光滑液柱。随着喷注压降的升高,液柱的长度逐渐增大;主流气体流经液柱发生三维绕流,在射流附近和近壁面区域形成不断演化的反转涡对,反转涡对的形成加速了液体射流一次破碎过程。     

可重复使用热防护材料应用与研究进展

可重复使用热防护系统是为高速重复使用飞行器而发展的关键性技术,涵盖了地球大气环境及非地球大气环境下的弹道式再入、高马赫数巡航等应用场景。根据现有高马赫数飞行器热防护现状,对高马赫数飞行器的主要热防护系统类型、特点和使用场景进行了简要介绍。在此基础上,结合国外里程碑式可重复使用飞行器（X-15、SR-71、航天飞机、X-33、X-37B、Spaceliner等）,梳理了可重复使用热防护材料的应用与研究进展,论述了代表性可重复使用热防护材料的发展、性能、研制进度、特点及应用前景。对国外在可重复使用热防护材料研制中的设计及发展思路,以及所存在的主要问题进行了总结归纳,为可重复使用热防护材料未来的发展提供了思路。     

基于PIV技术的单圆孔脉冲射流流场特征

对稳态射流及脉冲射流冲击靶板时的流场特性结构进行了探索和分析。采用高频粒子图像测速技术,在射流管口到冲击靶板间距为6倍管径的条件下,对稳态射流进口雷诺数为6 000的稳态射流及脉冲频率为20 Hz的脉冲射流进行了实验测量,得到了射流核心区、壁面射流区及滞止区内的速度分布。研究发现:①由于射流剪切作用的影响,脉冲射流核心区的最大轴向脉动速度为稳态射流的3倍。②滞止区内,由于射流的剪切作用和壁面的滞止作用,导致了脉冲射流轴向速度梯度最大为稳态射流的2倍,同时,滞止区内的最大脉动速度是稳态射流脉动速度的3倍。③脉冲射流对壁面的卷吸以及旋涡的产生和传播过程,破坏了壁面射流区稳定的速度边界层。相比稳态射流,脉冲射流的流场增加了湍流相干结构的含能并产生周期性的大尺度卷吸涡。     

Fluid structure interaction simulation of supersonic parachute inflation by an interface tracking method

An Arbitrary Lagrangian–Eulerian (ALE) approach with interface tracking is developed in this paper to simulate the supersonic parachute inflation. A two-way interaction between a nonlinear finite element method and a finite volume method is accomplished. In order to apply this interface tracking method to problems with instantaneous large deformation and self-contact, a new virtual structure contact method is proposed to leave room for the body-fitted mesh between the contact structural surfaces. In addition, the breakpoint due to the fluid mesh with negative volume is losslessly restarted by the conservative interpolation method. Based on this method, fluid and structural dynamic behaviors of a highly folded disk-gap-band parachute are obtained. Numerical results such as maximum Root Mean Square (RMS) drag, general canopy shape and the smallest canopy projected areas in the terminal descent state are in accordance with the wind tunnel test results. This analysis reveals the inflation law of the disk-gap-band parachute and provides a new numerical method for supersonic parachute design.     

Sensitivity analysis of flowfield modeling parameters upon the flow structure and aerodynamics of an opposing jet over a hypersonic blunt body

Implementation of an opposing jet in design of a hypersonic blunt body significantly modifies the external flowfield and yields a considerable reduction in the aerodynamic drag. This study aims to investigate the effects of flowfield modeling parameters of injection and freestream on the flow structure and aerodynamics of a blunt body with an opposing jet in hypersonic flow. Reynolds-Averaged Navier-Stokes (RANS) equations with a Shear Stress Transport (SST) turbulence model are employed to simulate the intricate jet flow interaction. Through utilizing a Non-Intrusive Polynomial Chaos (NIPC) method to construct surrogates, a functional relation is established between input modeling parameters and output flowfield and aerodynamic quantities in concern. Sobol indices in sensitivity analysis are introduced to represent the relative contribution of each parameter. It is found that variations in modeling parameters produce large variations in the flow structure and aerodynamics. The jet-to-freestream total-pressure ratio, jet Mach number, and freestream Mach number are the major contributors to variation in surface pressure, demonstrating an evident location-dependent behavior. The penetration length of injection, reattachment angle of the shear layer, and aerodynamic drag are also most sensitive to the three crucial parameters above. In comparison, the contributions of freestream temperature, freestream density, and jet total temperature are nearly negligible.